Hi, I am working on my 2004 Suzuki Eiger 400 manual 4x4. I need to split the case because the bevel gears are broken and I need a little help. The first problem is the flywheel, do I need to take the flywheel off? If I do how, I took the allen bolts out but I will probably need a puller.

I have removed all the parts on both sides I assume, as well as the cylinder assy. I will take some pics and upload them in a minute. But I could use a repair manual or some step by step instructions, as although, I have done many small engine, I have never done a ATV.

 

Don't think I have ever split the crankcase on an Eiger/KQ but I wouldn't have thought the flywheel would need to come off. They can be insanely tight and I had trouble with one, even after borrowing the official workshop tool. I wouldn't even think of dismantling one with out the manual. You are extremely lucky if you got all those washers gears/spacers off so you know how to put them back. There are also traps for the unwary, for example, the gears need to go back on so the oil holes line up with the holes in the shafts, on a Honda you can fit 'em any way round.

 

So an update here. I got the case split and put in new bevel gears and bearings. Put everything back together but I am having some trouble with the clutches.

If I try to turn the wet clutch clockwise it will turn the engine as well and from my understanding it should only spin the bell housing. I double checked the bearing to make sure it is in the correct way and it is. I am not sure if I did something wrong but I don't think I did. If someone has done this before and know what is correct please let me know.

 

I've tried working this out before, it makes your head hurt, and the easy way is to spin the engine over on the starter. The outer part of the centrifugal and the secondary clutch shouldn't move, or at least turn slower than the crankshaft, but try turning the outer part of the centrifugal in that direction with engine stopped and it should turn the crank.